Method of manufacturing a member, optical member and optical element

ABSTRACT

An optical member having a concentric diffraction surface facing the outside, wherein the projection having a inclined surface concentric to the diffraction surface having an angle of inclination θ smaller than the angle of inclination ϕ is provided outside the diffraction surface having the largest ϕ, so that an interference of a cutting tool is avoided, and simultaneously, deterioration of a surface roughness may be restrained.

BACKGROUND OF THE INVENTION

Field of the Invention

This disclosure relates to a method of manufacturing a member havingconcentric surfaces including a diffraction optical element or adiffraction optical element forming die used for an optical equipmentsuch as a camera and a video, an optical member having a diffractiongrating, and an optical element.

Description of the Related Art

An optical member having a diffraction grating, for example, adiffraction optical element, has characteristics such as having anopposite dispersing property to that of the refraction optical elementand contributing to achieve a compact optical system that a refractionoptical element including lens and prisms lacks, and hence is used invarious optical systems such as optical instruments.

A method of manufacturing an optical member having a diffraction gratingis disclosed in Japanese Patent Laid-Open No. 11-197902. Specifically,when forming the shape of a diffraction surface while rotating adiffraction surface to be cut and a cutting tool relatively to eachother and translating simultaneously, an inclined surface having adiffracting function is cut by using a side cutting edge having ashorter length than the inclined surface having the diffractingfunction. Japanese Patent Laid-Open No. 11-197902 also discloses thatthe cutting tool is attached so that a longitudinal direction of theside cutting edge forms an angle of 30 or smaller with respect to theinclined surface, and the diffraction surface to be cut is relativelymoved at an angle of 30 degrees or smaller from a lower side to a higherside of the inclined surface to achieve a cutting process.

Technical Problem

Japanese Patent Laid-Open No. 11-197902 discloses the optical memberincluding a diffraction grating having the same characteristic as aconcave lens, specifically, the optical member having a diffractionsurface facing inward and an inclination of outer grating and inclinedmore on the outer side. In a case where this method is applied to anoptical member, for example, a plastic lens, by the diffraction gratinghaving the same characteristics as a convex lens (hereinafter, referredto as a projecting grating), there arises the following subject. Here,the optical member on the basis of the projecting grating means aprojecting member provided with the diffraction grating having thediffraction surface facing outward and inclined more on the outer side.

In order to process the diffraction surface of the projecting gratingfrom the lower side to the higher side, a distal end of the cutting toolneeds to reach the cutting tool to a lowermost point of the diffractionsurface of a grating closest to an outer peripheral end portion(hereinafter an outermost grating) while proceeding from the outerperipheral end portion toward a center of the plastic lens. In order tofinish a surface roughness from the outer peripheral end portion to theoutermost grating efficiently, a gap angle formed between the sidecutting edge of the cutting tool and a cross-sectional surface verticalto an axis of rotation needs to be reduced to set a feeding speed asfast as possible. However, if the gap angle is smaller than theinclination of the diffraction surface of the outermost grating, thecutting tool (an opposite side to the distal end of a tool of the sidecutting edge) interferes with the diffraction surface of the outermostgrating. In order to avoid this interference, increasing the gap angleand lowering the feeding speed of the cutting tool are conceivable.However, since a processing efficiency is lowered and the gap angle isincreased so that a crushing effect of the cutting surface by the sidecutting edge (hereinafter, referred to as a burnishing effect) is alsolowered, there is a case where the surface roughness is deteriorated.

If the outermost grating has a shape failure due to the interferencewith the tool, an optical performance of the processed plastic lens maybe lowered. If there is the shape failure of the outermost grating andthe surface roughness from the outer peripheral end portion to theoutermost grating is deteriorated, an appearance quality of the opticalmember is varied so that the appearance quality may be lowered.

This disclosure provides a method of manufacturing a member having adesired projecting grating, an optical member, and an optical element.

SUMMARY OF THE INVENTION

This disclosure provides a method of manufacturing a member by rotatingan object to be processed and processing a concentric surface whilemoving a cutting tool from an outer peripheral end portion of the objectto be processed toward a center of rotation, including: a first step ofmoving the cutting tool so that a gap angle formed between a feedingdirection and a side cutting edge of the cutting tool has a constantangle α₁ to process a surface having an angle of inclination θ₀; asecond step of moving the cutting tool so that the gap angle becomes aconstant angle α₂ to process a surface having an angle of inclination θafter the first step; and a third step of moving the cutting tool sothat the gap angle becomes a constant angle α₃ to process a surfacehaving an largest angle of inclination ϕ after the second process,wherein the gap angles α₁, α₂, and α₃ are larger than 0 degree and notlarger than 4 degrees, the angles of inclination θ₀, θ, and ϕ have arelationship of θ₀<θ<ϕ, and the angle of inclination θ is smaller thanthe angle α₁.

The optical member of this disclosure is an optical member having aconcentric diffraction surface facing the outward, wherein theprojection having a inclined surface concentric to the diffractionsurface having an angle of inclination θ smaller than the angle ofinclination ϕ is provided outside the diffraction surface having thelargest angle of inclination ϕ.

The optical element of this disclosure is molded by a membermanufactured by the above-described method of manufacturing a member.

The optical element of this disclosure includes a member obtained bymolding the member manufactured by the above-described method ofmanufacturing the member, and a member molded by pouring a resin in themember.

Further features of the present invention will become apparent from thefollowing description of exemplary embodiments with reference to theattached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are schematic drawings of a method of manufacturing amember of this disclosure.

FIG. 2A is a schematic drawing of a flat surface cutting process.

FIG. 2B is a schematic drawing of a cutting process for cutting adiffraction optical element forming die.

FIGS. 3A to 3C are examples of an optical member having a diffractiongrating of this disclosure.

FIGS. 4A to 4D illustrate other examples of the optical member havingthe diffraction grating of this disclosure.

FIG. 5A is a schematic drawing of a method of manufacturing inComparative Example 1.

FIG. 5B is a schematic drawing of a method of manufacturing inComparative Example 2.

FIG. 6 is a schematic drawing of a common method of manufacturing inExample 2 and Comparative Example 3.

FIG. 7 is a graph illustrating a surface roughness in Example 1.

FIG. 8 is a graph illustrating a surface roughness in Example 2.

DESCRIPTION OF THE EMBODIMENTS First Embodiment

A first embodiment, which is an example of a method of manufacturing amember of this disclosure will be described with reference to thedrawings.

FIG. 2A is a schematic drawing of a flat surface cutting process.Reference numeral 300 denotes an object to be processed, referencenumeral 1 denotes a cutting tool, reference numeral 2 denotes a tooltip, reference numeral 3 denotes a tool tooth face, and reference sign fdenotes a feeding direction of the cutting tool. First of all, thedisc-shaped object to be processed 300 is mounted on a rotated principalaxis of an ultraprecision processing machine, which is not illustrated.The cutting tool 1 processes a projecting grating on a surface of theobject to be processed 300 while being moved from an outer peripheralend portion of the object to be processed 300 to a center of rotationthereof with respect to the objet to be processed 300 rotating about anoptical axis at a high speed to manufacture an optical member. Adirection perpendicular to a paper plane is defined as a cuttingdirection, and a left-and-right direction of the paper plane is definedas a feeding direction.

Conceivable examples of the member include a glass lens, a plastic lens,a composite lens having a plastic layer on a glass surface, and a lensmolding die provided with a metal plating of Ni system and Cu system ona surface of an SUS system base material.

Preferable examples of the material of the tool tip 2 includehigh-hardness materials such as diamond or cBN and, specifically,monocrystal diamond is preferable as the material of the tool tip 2because a very sharp cutting ridge line can be formed.

FIGS. 1A and 1B are drawings for explaining a processing surface duringa processing of object to be processed 300 described in FIG. 2A, andmovement of a tool when processing the processing surface thereof. FIG.1A is a top view of the object to be processed 300 in the course ofprocessing. FIG. 1B is a drawing illustrating a cross section of an areaB taken along the line IB-IB in FIG. 1A and a movement of the tool.Specifically, for example, FIG. 1A illustrates a state in which theprocess is proceeded half-way through the optical member illustrated inFIG. 3 described later. In other words, when the process is completed,the optical member as illustrated in FIG. 3 is manufactured. FIG. 1B isa drawing corresponding to a cross-section of a part IIIC of the opticalmember illustrated in FIG. 3A to 3B.

Reference numeral 6 denotes an outermost diffraction grating, andreference numeral 5 denotes an outermost diffraction surface. Thegrating 6 and the surface 5 are formed into a concentric shape.Reference sign ϕ denotes an angle of inclination of the surface 5 (anangle formed between the surface 5 and a surface perpendicular to theoptical axis), and has the largest angle of inclination in comparisonwith a surface which becomes the diffraction surface inside (the leftside of the paper plane) of the surface 5, which is to be processedafter the surface 5. Hereinafter, the surface 5 having the largest angleof inclination is referred to as “largest inclination surface”.

Reference numeral 10 denotes an outer peripheral surface, and an angleof inclination θ₀ (an angle formed between the outer peripheral surfaceand a surface perpendicular to an optical axis) is preferably 0 degree.However, if a relationship described later, ϕ>θ>θ₀ is satisfied, theangle is not limited to 0 degree. The case where the angle ofinclination θ₀ is 0 degree is referred to as a flat surface here.

Reference numeral 8 denotes an inclined surface of a projection 7 formedadjacently to the grating 6 having the largest inclination surface 5.The angle of inclination θ of an inclined surface 8 (an angle formedbetween the inclined surface 8 and a surface perpendicular to theoptical axis) is smaller than an angle of inclination ϕ of the largestinclination surface 5 adjacent thereto with a vertical wall (connectingsurface) 9 interposed therebetween. In the related art, at least aportion adjacent to the outside of the largest inclination surface 5 ofthe outer peripheral surface 10 is a flat surface. However, thisdisclosure is characterized in that the projection 7 including theinclined surface having an angle of inclination smaller than the angleof inclination ϕ of the largest inclination surface 5 between the outersurface 10 and the largest inclination surface 5. In other words, theprojection 7 having an inclined surface at an angle of inclination θwhich satisfying a relationship of ϕ>θ>θ₀ is formed between the outerperipheral surface 10 at the angle of inclination θ₀ and the largestinclination surface 5 having an angle of inclination ϕ. Accordingly, aninterference of the tool with respect to the largest inclinationdiffraction surface 5 may be prevented. In this embodiment, the casewhere the outer peripheral surface 10 extends to the outer peripheralend portion of the object to be processed is illustrated. However, theeffects of this disclosure is achieved as long as at least the portionwhich is in no danger of interference of the cutting tool adjacent tothe projection 7 is the outer peripheral surface 10. No problem occurseven if either the projection-shaped portion, the depressed-shapedportion, or the inclined surface is formed on an outer peripheralportion of the outer peripheral surface 10 which is in no danger ofinterference of the cutting tool.

A method of manufacturing the outer peripheral surface, the inclinedsurface, and the largest inclination surface will be described.

First Step

An outer peripheral surface 10 is processed first. The process of theouter peripheral surface 10 is referred to as a first step here.

Reference numeral 2 a denotes an inclination of a tool tip distal endportion in the first step in which the process of cutting the outerperipheral surface 10 is performed. Reference numeral 3 denotes a tooltooth face, and reference numeral 4 denotes a side cutting edge of thecutting tool. At the distal end portion of the tool tip 2 has two ormore cutting edges in a tool feeding direction, and the cutting edgeclosest to the distal end of the tool. A length of the side cutting edge4 is shorter than a length of the largest inclination surface 5.

For setting process conditions, if a surface roughness exceeds PV 20 nm,the optical performance may easily be generated, and hence a requiredsurface roughness is not higher than PV 20 nm. If variations in thesurface roughness exceeds ±5 nm, lowering of the appearance quality mayoccur very often. Therefore, the process condition needs to be set onthe basis of the above-described two points. The following expression isan expression for obtaining a logical surface roughness h in the cuttingprocess using a blade tip shaped cutting tool, where P is a distancethat the tool proceeds in the feeding direction while the object to beprocessed makes one turn (hereinafter, referred to as a feed pitch ofthe tool), and α is a gap angle. The following expression is used to setthe logical surface roughness from the feed pitch P of the tool and thegap angle α,h=P×tan α.

The first step is the processing of the outer peripheral surface 10. Thetool tip distal end portion 2 a cuts into an object to be processed 300from the outer peripheral end portion of the object to be processed 300rotating at a high speed. The cutting process is continued to alowermost point S₁ of the inclined surface 8 of the projection 7 so thatthe gap angle formed between the tool feeding direction (direction oftravel) f₁ and the side cutting edge 4 in the process of the outerperipheral surface 10, and the gap angle becomes a certain angle α₁. Thelogical surface roughness in the cutting process is geometricallydetermined by the gap angle and a tool feeding speed. However, in orderto finish the surface roughness of the outer peripheral surface 10efficiently, it is desirable to set the tool feeding speed to a value asfast as possible after the gap angle α₁ has set as small angle aspossible.

In the case where the object to be processed 300 is a glass lens, thecutting thickness achieved by the side cutting edge 4 may be reduced toa sub-micron level which allows ductile mode cutting by reducing the gapangle α₁. Conceivable examples of the member include manufacturing aplastic lens, a composite lens having a plastic layer on the glasssurface, and a lens molding die provided with a metal plating of Nisystem and Cu system on the surface of the SUS system base material asthe member. In this case, a burnishing effect in the side cutting edge 4can be easily achieved by reducing the gap angle α₁. Therefore, reducingthe gap angle α₁ is important for performing the cutting process forcutting various materials to be cut in a stable manner in addition tothe reasons in terms of the processing efficiency. Specifically, the gapangle α₁ is an angle which satisfies a relationship of 0 degree<α₁<4degrees, and is set to an angle larger than the inclination θ of theinclined surface 8 so as not to hit the inclined surface 8 in the nextstep.

Second Step

Consecutively after the process of the outer peripheral surface 10, theinclined surface 8 is processed. The process of the inclined surface 8is referred to as a second step here. Reference sign 2 b denotes aninclination of a tool tip distal end portion in the second step in whichthe process of cutting the inclined surface 8 is performed. Theinclination θ of the inclined surface 8 is set arbitrarily as long asbeing an inclination smaller than the gap angle α₁ of the tool whenprocessing the outer peripheral surface 10. The cutting tool is moved sothat the gap angle formed between a tool feeding direction f₂ and theside cutting edge 4 becomes a constant angle α₂ from a lower side to anupper side of the inclined surface 8 having an angle θ smaller than thegap angle α₁ to perform the cutting process. A cutting thickness by theside cutting edge 4 may be reduced efficiently to a sub-micron levelwhich allows a ductile mode cutting and the burnishing effect of theside cutting edge 4 is obtained easily by reducing the gap angle α₂ likethe gap angle α₁. Therefore, reducing the gap angle α₂ is important forperforming the cutting process for cutting various materials to be cutin a stable manner. Specifically, the gap angle α₂ is set to 0degree<α₂≤4 degrees. In other words, the gap angle α₂ is preferablelarger than 0 degree and not larger than 4 degrees. The inclination θ ofthe inclined surface 8 is set to be smaller than the gap angle α₁ in thefirst step, so that an opposite side to the distal end of the tool ofthe side cutting edge 4 does not interfere with the inclined surface 8,and the gap angle α₂ is smaller than the gap angle α₁ by θ at thelowermost point of the inclined surface 8. Therefore, a process ofvarious objects to be cut is achieved in a more stable manner than thefirst step. If the feeding speed of the second step and the feedingspeed of the first step are the same, the surface roughness is improvedmore. However, if the logical roughness between the outer peripheralsurface 10 and the inclined surface 8 are different, the variations arerequired to fall within a range of ±5 nm. If the surface roughnessbetween the outer peripheral surface 10 and the inclined surface 8 needsto be the same, the cutting tool is rotated clockwise about the axis ofrotation perpendicular to the paper plane by θ to set the gap angle α₂and the gap angle α₁ to the same angle, and then the process of theinclined surface 8 is performed at the same feeding speed. The surfaceroughness of the outer peripheral surface 10 may be set to that of theinclined surface 8 by increasing the feeding speed in the second step.

Third Process

After the process of the inclined surface 8, a vertical wall 9 whichconnects the inclined surface 8 with a lowermost point S₃ of the largestinclination surface 5 is processed, and consecutively, the largestinclination surface 5 is processed. The process of the largestinclination surface 5 located outermost among a number of surfaces whichform the diffraction surface and having a largest angle of inclinationis referred to as a third step here. Reference numeral 2 c denotes aninclination of a tool tip distal end portion in the third step in whichthe process of cutting the largest inclination surface 5 is performed.

The cutting tool is moved so that the gap angle formed between a toolfeeding direction f₃ and the side cutting edge 4 becomes a constantangle α₃ from a lower side to a higher side of the largest inclinationsurface 5 to perform the cutting process. The cutting thickness by theside cutting edge 4 may be reduced efficiently to a sub-micron levelwhich allows the ductile mode cutting and the burnishing effect of theside cutting edge 4 is obtained easily by reducing the gap angle α₃ likethe gap angle α₁ and the gap angle α₂. Therefore, reducing the gap angleα₃ is important for performing the cutting process for cutting variousmaterials to be cut in a stable manner in addition to the reason interms of the process efficiency. Specifically, the gap angle α₃ is setto 0 degree<α₃≤4 degrees. In other words, the gap angle α₃ is preferablelarger than 0 degree and not larger than 4 degrees. At this time, thegap angle α₃ and the tool feeding speed are preferably set to the sameas the first step and the second step, or to the comparative level toperform the process. Accordingly, the surface roughness of the outerperipheral surface 10, the inclined surface 8, and the largestinclination surface 5 become the same or the comparative level, so thatvariations in appearance quality of the member depending on portions areavoided, and improvement of the appearance quality is expected. Thecutting tool is rotated clockwise about the axis of rotationperpendicular to the paper plane before processing the vertical wall 9which connects the highermost point of the inclined surface 8 and thelower point of the largest inclination surface 5 so that the gap angleα₃ becomes the same as or the comparative level to the gap angle α₁ andthe gap angle α₂ at the lowermost point of the largest inclinationsurface 5. Accordingly, interference of the side cutting edge 4 on theside opposite to the distal end of the tool with the largest inclinationsurface 5 when the vertical wall 9 is processed with the tool tip distalend portion 2 b at the posture in the second step depending on themagnitude of an inclination ϕ of the largest inclination surface 5 isprevented.

In the above-described embodiment, a method of manufacturing an opticalmember having a flat base (a surface connecting lowermost points of anumber of the diffraction surfaces is a flat surface) has beenexemplified. However, even an optical member having a depressed curvedbase as illustrated in FIG. 2B (a surface connecting the lowermostpoints of a number of the diffraction surfaces is a depressed surface),it is apparent that this disclosure may be applied by setting the toolfeeding direction to a direction of tangent line of the shape to beprocessed. Even an optical member having a projecting curved base, it isapparent that this disclosure may be applied by setting the tool feedingdirection to the direction of tangent line of the shape to be processed.

A member molded by pouring a resin to a member manufactured by themethod of manufacturing the member described in this embodiment may alsobe used as the optical element.

In addition, the member molded by pouring the resin to the membermanufactured by the method of manufacturing the member described in thefirst embodiment and a member molded by further pouring the resin intothe above-described molded member may also be used as an opticalelement.

Second Embodiment

An example of the optical member of this disclosure will be describedwith reference to the drawings.

FIGS. 3A to 3C are drawings illustrating an example of the opticalmember of this disclosure. FIG. 3A is a top view and FIG. 3B is across-sectional view taken along the line IIIB-IIIB in FIG. 3A. FIG. 3Cis an enlarged drawing of a portion IIIC in FIG. 3B. Reference numeral35 denotes a largest inclination diffraction surface, reference numeral36 denotes a diffraction grating having the largest inclinationdiffraction surface 35. The diffraction grating is formed into aconcentric shape. In FIGS. 3A to 3C, the number of the illustrateddiffraction gratings is smaller than the actual number for the sake ofsimplification. However, a large number of the diffraction gratings maybe provided. Reference numeral 37 denotes a projection having atriangular cross-sectional shape obtained by cutting along a planepassing through an optical axis and being parallel to the optical axis,which is adjacent to the outside of the diffraction grating having thelargest inclination diffraction surface 35. Reference numeral 38 denotesan inclined surface having an angle of inclination smaller than thelargest inclination diffraction surface 35, reference numeral 310denotes an outer peripheral surface on the outside of the projection 37,and reference numeral 330 denotes an optical member. Conceivableexamples of the optical member of this disclosure include a glass lens,a plastic lens, a composite lens having a plastic layer on the glasssurface, and a lens molding die provided with a metal plating of Nisystem and Cu system on the surface of the SUS system base material. Anoptical member molded by further transferring the member molded bytransferring the lens molding die is also included.

Reference sign ϕ denotes an inclination (angle of inclination) of thelargest inclination diffraction surface 35, and is an angle formedbetween the diffraction surface 35 and a plane perpendicular to theoptical axis. Reference sign θ is an inclination (angle of inclination)of the inclined surface 38 (an angle formed between the inclined surface38 and the plane perpendicular to the optical axis). Reference sign θ₀(not illustrated) denotes an inclination of the outer peripheral surface(an angle formed between the outer peripheral surface 310 and the planeperpendicular to the optical axis), and is smaller than θ, and θ₀ (notillustrated) may be 0 degree.

The embodiment is characterized in that the projection 37 having theinclined surface 38 having an angle of inclination θ smaller than theangle of inclination ϕ of the largest inclination diffraction surface 35is provided on the outside of and adjacent to the diffraction grating 36having the largest inclination diffraction surface 35. An example inwhich the cross-sectional shape of the projection (the cross-sectionalshape taken along a plane passing through, and being parallel to, theoptical axis) is a triangular shape in this embodiment has beendescribed. However, the invention is not limited thereto.

FIGS. 4A to 4D illustrate other examples of the optical member havingthe diffraction grating of this disclosure. For the sake ofsimplification, a cross-sectional shape of part of the optical memberwill be illustrated. The same portions as FIGS. 3A to 3C are denoted bythe same reference numerals, and description thereof is omitted.

In FIG. 4A, an example in which reference numeral 37 a denotes across-sectional shape of the projection (the cross-sectional shape takenalong a plane passing through, and being parallel to, the optical axis)being a square shape. Reference numeral 38 a denotes an inclined surfaceof the projection 37 a connected to the outer peripheral surface 310,and reference sign θ₁ denotes an inclination of the inclined surface 38a.

In FIG. 4B, an example in which reference numeral 37 b denotes across-sectional shape of the projection (the cross-sectional shape takenalong a plane passing through, and being parallel to, the optical axis)being a square shape. Reference numerals 38 b ₁ and 38 b ₂ are inclinedsurfaces of the projection 37 b having different angles of inclination.Reference numeral 38 b 1 denotes an inclined surface connected to theouter peripheral surface 310, and θ₂ denotes an angle of inclination ofthe inclined surface 38 b ₁.

In FIG. 4C, an example in which reference numeral 37 d denotes across-sectional shape of the projection (the cross-sectional shape takenalong a plane passing through, and being parallel to, the optical axis)being a pentagonal shape. Reference numerals 38 c ₁, 38 c ₂, and 38 c ₃are inclined surfaces of the projection 37 c having different angles ofinclination. Reference numeral 38 c ₁ denotes an inclined surfaceconnected to the outer peripheral surface 310, and θ₃ denotes an angleof inclination of the inclined surface 38 c ₁.

In FIG. 4D, an example in which reference numeral 37 d denotes across-sectional shape of the projection (the cross-sectional shape takenalong a plane passing through, and being parallel to, the optical axis)being partly a inclined pentagonal shape. Reference numeral 38 d denotesa curved surface connected to the outer peripheral surface 310.Reference numeral 311 denotes a tangent line at the lowermost point ofthe curved surface 38 d, and θ₄ denotes an inclination of the tangentline 311.

As illustrated in FIGS. 4A to 4C, in the case where the projection has apolygonal shape, if inclinations (θ₁, θ₂, and θ₃) of the inclinedsurfaces (38 a, 38 b ₁, and 38 c ₁) connected to the peripheral surface310 are smaller than the inclination ϕ of the largest inclinationdiffraction surface 35, the object of this disclosure is achieved.Furthermore, the inclination of the inclined surface located between theinclined surfaces (38 a, 38 b ₁, and 38 c ₁) connected to an outerperipheral portion 310 and the highermost points of the projections (37a, 37 b, and 37 c) are preferably smaller than the inclination ϕ of thelargest inclination diffraction surface 35 as well.

As illustrated in FIG. 4D, in the case where the projection has aprojecting curved surface 38 d connected to the outer peripheral surface310, if the inclination of a tangent line θ₄ at the lowermost point ofthe curved surface 38 d is smaller than the inclination ϕ of the largestinclination diffraction surface 35, the object of this disclosure isachieved. The curved surface 38 d may be a depressed curved surface, ora curved surface including depressions and projections mixed therein.

The optical member of the second embodiment is manufactured by themethod of manufacturing a member described in the first embodiment. Inaddition, the optical member of the second embodiment may be the membermolded by further pouring the resin in the member molded by pouring theresin in the member manufactured by the method of manufacturing themember described in the first embodiment.

EXAMPLES

Subsequently, examples of this disclosure will be described.

Example 1

In Example 1, an example in which a diffraction optical element formingdie having a projecting grating in a depressed base shape ismanufactured by a method of manufacturing the member illustrated in thefirst embodiment will be described with Comparative Examples.

FIG. 2B is a schematic drawing of a cutting process for cutting thediffraction optical element forming die. As the object to be processed300, a member plated with a NiP on the surface of a SUS system basematerial having a depressed base shape was used. A mono-crystal diamondwas used as a tool tip 2. The object to be processed 300 was mounted ona rotated principal axis of an ultraprecision processing machine, whichwas not illustrated. The cutting tool 1 was mounted on theultraprecision processing machine, which was not illustrated, so thatthe movement along the orthogonal double axes existing in parallel to atooth face 3, and the rotation about the axis of rotation perpendicularto the tooth face 3 were enabled. Subsequently, the object to beprocessed 300 was rotated at a high speed, and a projecting grating wasformed by processing the surface of the object to be processed 300 whilefeeding the cutting tool 1 from the outside toward the center of theobject to be processed 300, thereby having manufactured a member (metaldie).

At this time, as illustrated by a solid line and a double-dashed chainline in FIG. 2B, the cutting tool 1 was rotated about the axis ofrotation as needed by using the axis of rotation while being fed in thefeeding direction f of the tool following the intended processed shape.Accordingly, the cutting tool 1 is capable of maintaining a certaininclination with respect to the feeding direction f of the tool from astart to an end of process. In all the processes illustrated in Example1 and Example 2 described later, the tool posture control, describedabove was used.

A result of process will be shown in Table 1. Results of the process areillustrated in Table 1

TABLE 1 largest inclination outer diffraction peripheral surfaceprojection surface result of ϕ α₃ P₃ θ α₂ P₂ α₁ P₁ process Example 1 53.5 250 nm 0.5 3.5 250 nm 4 200 nm ∘ Compar- 5 3.5 250 nm — — — 8.5 100nm x ative Ex- ample 1 Compar- 5 3.5 250 nm — — — 4 200 nm x ative Ex- ↓↓ ample 2 8.5 100 nm

In Table 1, ϕ is an inclination of the largest inclination surface 5, θis an inclination of the inclined surface of the projection 7. α₁ is agap angle in the process of the outer peripheral surface 10, α₂ is a gapangle in the process of the inclined surface 8 of the projection 7, andα₃ is a gap angle in the process of the largest inclination surface 5.P₁ is a distance that the tool proceeds in the feeding direction duringone turn of the object to be processed on the outer peripheral surface(hereinafter, referred to as a feed pitch of the tool), P₂ is a feedpitch of the tool on the inclined surface 8 of the projection, and P₃ isa feed pitch of the tool on the largest inclination surface 5.

The contents of the respective processes will be described below.

First of all, Example 1 will be described with reference to FIGS. 1A and1B. This example was implemented on the depressed base. However, for thesake of simplification, description will be given with reference toFIGS. 1A and 1B, having the flat base shape. In the diffraction opticalelement forming die which is to be processed this time, since theinclination ϕ of the largest inclination diffraction surface 5 was 5degrees, the triangular projection 7 adjacent to the outside of thelargest inclination diffraction grating 6 and various processingconditions were set in detail.

For setting process conditions, if a surface roughness specifically forforming the diffraction surface (for example, the largest inclinationsurface 5) exceeds PV 20 nm, lowering of the optical performance mayeasily occur, and hence a required surface roughness is not higher thanPV 20 nm. If variations in the surface roughness of a portion other thanthe vertical wall 9 exceeds ±5 nm, lowering of the appearance qualitymay occur very often. Therefore, the process condition was set on thebasis of the above-described two points. The following expression is anexpression for obtaining a logical surface roughness h in the cuttingprocess using a blade tip shaped cutting tool, where P is a feed pitchof the tool, and a is a gap angle. The following expression was used toset the feed pitch P of the tool and the gap angle α of the tool so thatthe logical surface roughness becomes a value on the order of PV 15 nm.h=P×tan α.

In Example, 1, after the tool tip distal end 2 a has reached thelowermost point of the inclined surface 8 of the projection 7 whilemaintaining the gap angle α₁ constant, and the inclined surface 8 wasprocessed while maintaining the gap angle 2 constant and the largestinclination surface 5 was processed while maintaining the gap angle α₃constant in this order.

At this time, the number of rotation of an optical member 30 was set to3000 min−1, and in the process of the outer peripheral surface 10, thegap angle α₁ was set to 4 degrees at which the burnishing effect isexpected, and the tool feeding speed was set to 0.6 mm/min(P₁=200 nm).The inclination θ of the inclined surface 8 of the projection 7 was setto 0.5 degrees, the gap angle α₂ during the process of the inclinedsurface 8 and the gap angle α₃ during the process of the largestinclination surface 5 was set to 3.5 degrees, and the tool feeding speedin the process of the inclined surface 8 and the largest inclinationsurface 5 was set to 0.75 mm/min (P₂=P₃=250 nm). An edge width of theused side cutting edge 4 of the cutting tool was set to 3 μm, and anangle of the edge of the distal end of the tool was set to 80 degrees.In Comparative Example 1 and Comparative Example 2 described later aswell, the logical surface roughness other than the vertical wall 9, theinclination ϕ of the largest inclination surface 5, the number ofrotations of the optical member 30, the edge width of the side cuttingedge 4, and the edge angle of the distal end of the tool are common.

Subsequently, Comparative Example 1 will be described with reference toFIG. 5A. Although Comparative Example 1 was implemented in thedepression surface base in the same manner as Example 1, FIG. 5Aillustrates a flat base shape for the sake of simplification. InComparative Example 1, after the tool tip distal end 2 a has reached thelowermost point of the largest inclination surface 5 while maintainingthe gap angle α₁ constant, and the largest inclination surface 5 wasprocessed while maintaining the gap angle α₃ constant.

At this time, the gap angle α₁ during the process of the outerperipheral surface 10 was set to 8.5 degrees, and the tool feeding speedwas set to 0.3 mm/min (P₁=100 nm). The gap angle α₃ during the processof the largest inclination surface 5 was set to 3.5 degrees, and thetool feeding speed was set to 0.75 mm/min (P₃=250 nm).

Subsequently, Comparative Example 2 will be described with reference toFIG. 5B. Although comparative Example 2 was also implemented in thedepression surface base in the same manner as Example 1, FIG. 5Billustrates a flat base shape for the sake of simplification. InComparative Example 2, the tool tip distal end 2 a proceeded the processtoward the lowermost point of the largest inclination surface 5 whilemaintaining the gap angle α₁ smaller than the inclination ϕ of thelargest inclination surface 5. However, if the tool tip distal end 2 areaches the lowermost point of the largest inclination surface 5 as-is,the side cutting edge 4 on the opposite side to the distal end of thetool interfere with the largest inclination surface 5. Therefore, in aleft area 12 of the outer peripheral surface 10, the process isproceeded to the lowermost point of the largest inclination surface 5while rotating the cutting tool about the axis of rotation perpendicularto the paper plane. Subsequently, the largest inclination surface 5 wasprocessed while maintaining the gap angle α₃ constant.

At this time, in the process of the outer peripheral surface 10, the gapangle α₁ was set to 4 degrees at which the burnishing effect isexpected, and the tool feeding speed was set to 0.6 mm/min (P₁=200 nm),and the gap angle α₁ was increased gradually in the left area 12 of theouter peripheral surface 10. The gap angle α1 was set to become 8.5degrees when reaching the lowermost point of the largest inclinationsurface 5. The tool feeding speed in the left area 12 of the outerperipheral surface 10 is gradually reduced as the gap angle increases sothat the logical surface roughness becomes a value on the order of PV 15nm, and becomes 0.3 mm/min (P₁=100 nm) when reaching the lowermost pointof the largest inclination surface 5. The gap angle α₃ during theprocess of the largest inclination surface 5 was set to 3.5 degrees, andthe tool feeding speed was set to 0.75 mm/min (P₃=250 nm).

In the result of processing shown in Table 1, the cases where thesurface roughness of the outer peripheral surface 10, the inclinedsurface 8 of the projection 7 (but not in Comparative Examples 1 and 2),and the largest inclination surface 5 were set to PV 20 nm or lower andvariations in the surface roughness of the measured portions was ±5 nmor smaller were marked with a circle. The cases where at least one ofthem was out of the above-described range were marked with a cross. Thesurface roughness was measured with an atomic force microscope (AFM).

FIG. 7 illustrates the result of measurement of the surface roughness inExample 1, Comparative Example 1, and Comparative Example 2. In Example1, the surface roughness at the three points at three points was nothigher than PV 20 nm, and variation widths were not larger than ±5 nm.In contrast, in Comparative Example 1, the surface roughness of thelargest inclination surface 5 was not higher than the PV 20 nm, but thesurface roughness of the outer peripheral surface 10 exceeds PV 20 nm.In Comparative Example 2, the surface roughness of the largestinclination surface 5 was not higher than PV 20 nm, but the surfaceroughness of the left area 12 of the outer peripheral surface exceeds PV20 nm. In Comparative Example 2, although the surface roughness of theouter peripheral surface 10 other than the left area 12 was on the orderof PV 15 nm. However, in the left area 12, it seemed that the surfaceroughness was deteriorated by the influence of the reduction of theburnishing effect due to the gradual increase of the gap angle α1. Fromthe result described above, it is confirmed that this disclosure iseffective.

Example 2

Example 2 as another example of this disclosure will be described. InExample 2, a diffraction optical element forming die having a projectinggrating in a depressed base shape is manufactured by a method ofmanufacturing the optical member having the diffraction gratingillustrated in the first embodiment. Points of view regarding the metalmold used for the process, the tool tip material, tool posture controlduring the process, and the logical source roughness are common toExample 1.

A result of process will be described Table 2.

TABLE 2 largest inclination outer diffraction peripheral surfaceprojection surface result of ϕ α₃ P₃ θ α₂ P₂ α₁ 1 process Example 2 5 4250 nm 3.9 4 200 4 200 nm ∘ Compar- 5 5 170 nm 4.9 5 5 170 nm x ativeEx- ample 3

In Table 2, ϕ is an inclination of the largest inclination surface 5, θis an inclination of the inclined surface of the projection 7. α₁ is agap angle in the process of the outer peripheral surface 10, α₂ is a gapangle in the process of the inclined surface 8 of the projection 7, andα₃ is a gap angle in the process of the largest inclination surface 5.P₁ is a feed pitch of the tool on the outer peripheral surface 10, P₂ isa feed pitch of the tool on the inclined surface 8 of the projection,and P₃ is a feed pitch of the tool on the largest inclination surface 5.The contents of the respective processes will be described below.

First of all, Example 2 and Comparative Example 3 will be described withreference to FIG. 6. Although Example 2 and Comparative Example 3 wereimplemented with the depressed base, FIG. 6 illustrates a flat baseshape for the sake of simplification.

In any of the processes, the tool tip distal end 2 a proceeded theprocess to the lowermost point of the inclined surface 8 of theprojection 7 while maintaining the gap angle α₁ constant, and thenrotated the cutting tool about the axis of rotation perpendicularly tothe paper plane from a posture of the tool tip 2 a′ illustrated by adouble-dashed chin line to a posture of the tool tip 2 b. Then, theprocess of the inclined surface 8 while maintaining the gap angle α₂constant and the process of the largest inclination surface 5 whilemaintaining the gap angle α₃ constant were followed. At this time, theinclination ϕ of the largest inclination diffraction surface 5 was 5degrees, the number of rotations of the optical member 30 was 3000min⁻¹, the edge width of the side cutting edge 4 of the used cuttingtool was 3 μm, and the edge angle of the distal end of the tool was 70degrees. On the basis of the above-described expression, the feed pitchP of the tool and the gap angle α of the tool was set so that thelogical surface roughness becomes a value on the order of PV 15 nm.

In Example 2, in the process of the outer peripheral surface 10, the gapangle α₁ was set to 4 degrees at which the burnishing effect isexpected, and the tool feeding speed was set to 0.6 mm/min (P₁=200 nm).The inclination θ of the inclined surface 8 of the projection 7 was setto 3.9 degrees, the gap angle α₂ during the process of the inclinedsurface 8 and the gap angle α₃ during the process of the largestinclination surface 5 was set to 4 degrees, and the tool feeding speedin the process of the inclined surface 8 and the largest inclinationsurface 5 was set to 0.6 mm/min (P₂=P₃=200 nm).

In Example 3, in the process of the outer peripheral surface 10, the gapangle α₁ was set to 5 degrees, and the tool feeding speed was set to0.51 mm/min (P₁=170 nm). The inclination θ of the inclined surface 8 ofthe projection 7 was set to 4.9 degrees, the gap angle α₂ during theprocess of the inclined surface 8 and the gap angle α₃ during theprocess of the largest inclination surface 5 was set to 5 degrees, andthe tool feeding speed in the process of the inclined surface 8 and thelargest inclination surface 5 was set to 0.51 mm/min (P₂=P₃=170 nm).

In the result of processing shown in Table 2, the cases where thesurface roughness of the outer peripheral surface 10, the inclinedsurface 8 of the projection 7, and the largest inclination surface 5 wasset to PV 20 nm or lower and variations in the surface roughness of themeasured portions were ±5 nm or smaller were marked with a circle. Incontrast, the cases where at least one of them was out of theabove-described range were marked with a cross. The surface roughnesswas measured with an atomic force microscope (AFM).

FIG. 8 illustrates the result of measurement of the surface roughness inExample 2, and Comparative Example 3. In Example 2, the surfaceroughness at the three points was not higher than PV 20 nm, andvariation widths were not larger than ±5 nm. In contrast, in ComparativeExample 3, the surface roughness at all the three points exceed PV 20nm. In Comparative Example 3, it seemed that the surface roughnessexceeded PV 20 nm because the inclination θ of the inclined surface 8 ofthe projection 7 was 4.9 degrees and the gap angle α₁ was obliged to beset to a exceed 4.9 degrees during the process of the outer peripheralsurface 10. Since the gap angle α₂ and the gap angle α₃ were determinedso as to follow the gap angle α₁, the surface roughness of the inclinedsurface 8 of the projection 7 and the largest inclination surface 5results in the same manner. From the results described above, it wasfound that the inclination θ of the inclined surface 8 of the projection7 set to 0<θ≤4 degrees was preferable.

The interference between the surface having a largest inclination andthe cutting tool is avoided, and deterioration of the surface roughnessof the outside of the surface having the largest inclination issuppressed.

While the present invention has been described with reference toexemplary embodiments, it is to be understood that the invention is notlimited to the disclosed exemplary embodiments. The scope of thefollowing claims is to be accorded the broadest interpretation so as toencompass all such modifications and equivalent structures andfunctions.

This application claims the benefit of Japanese Patent Application No.2014-186855 filed Sep. 12, 2014, which is hereby incorporated byreference herein in its entirety.

What is claimed is:
 1. A method of manufacturing a member by rotating anobject to be processed and processing a plurality of concentricprojections while moving a cutting tool from an outer peripheral endportion of the object to be processed toward a center of rotation, theobject having a flat surface at the outer peripheral end portion,comprising: a first step of moving the cutting tool so that a gap angleformed between a feeding direction of the cutting tool and a sidecutting edge of the cutting tool has a constant angle α₁ to process theflat surface; a second step of moving the cutting tool so that the gapangle becomes a constant angle α₂ to process a projection that has asurface having an angle of inclination θ and being adjacent to the flatsurface after the first step; and a third step of moving the cuttingtool so that the gap angle becomes a constant angle α₃ to process aprojection that has a surface having a largest angle of inclination ϕamong the plurality of concentric projections, the projection having thesurface having the largest angle of inclination ϕ being adjacent to theprojection having the surface having the angle of inclination θ, afterthe second step, wherein the gap angles α₁, α₂, and α₃ are larger than 0degree and not larger than 4 degrees, the angles of inclination θ and ϕhave a relationship of 0<θ<ϕ, and the angle of inclination θ is smallerthan the angle α₁.
 2. The method of manufacturing a member according toclaim 1, wherein the gap angle α₁, α₂, and α₃ are set to be the sameangle.
 3. The method of manufacturing a member according to claim 1,wherein the member includes one of a glass lens, a plastic lens, acomposite lens having a plastic layer on a grass surface, and a lensmolding die.
 4. An optical element molded by a member manufactured by amethod of manufacturing a member according to claim
 1. 5. An opticalelement comprising: a first part obtained by transferring the pluralityof concentric projections of a member manufactured by the method ofmanufacturing a member according to claim 1 to a resin; and a secondpart obtained by pouring a resin on the first part.
 6. An opticalequipment comprising the optical element according to claim 5.